Pharmaceutical carrier device suitable for delivery of pharmaceutical compounds to mucosal surfaces

ABSTRACT

The present invention relates to a pharmaceutical delivery device for application of a pharmaceutical to mucosal surfaces. The device comprises an adhesive layer and a non-adhesive backing layer, and the pharmaceutical may be provided in either or both layers. Upon application, the device adheres to the mucosal surface, providing localized drug delivery and protection to the treatment site. The kinetics of erodability are easily adjusted by varying the number of layers and/or the components.

The instant application is a continuation-in-part application ofPCT/US97/18605 filed Oct. 16, 1997 which is a PCT application claimingpriority from Ser. No. 08/734,519 filed Oct. 18, 1996.

FIELD OF THE INVENTION

The present invention relates generally to a water-erodablepharmaceutical carrier which adheres to mucosal surfaces for thelocalized delivery of pharmaceutical compounds and protection of thetreatment site.

BACKGROUND OF THE INVENTION

The localized treatment of body tissues, diseases, and wounds requiresthat the particular pharmaceutical component be maintained at the siteof treatment for an effective period of time. Given the tendency ofnatural bodily fluids to rapidly wash away topically appliedpharmaceutical components, the topical treatment of wet mucosal tissueshas been problematic. In the mouth, saliva, natural replacement of themucosal tissue, as well as, eating, drinking, and speaking movements aresome of the problems that have limited the effectiveness and residencetime of pharmaceutical carriers.

Bioadhesive carriers are known in the art and include gels, pastes,tablets, and films. These products, however, may lack one or several ofthe preferred characteristics for an efficient and commerciallyacceptable pharmaceutical delivery device. Some characteristics whichare preferred by users of bioadhesive carriers includewater-erodability; ease of handling and application to the treatmentsite; ease of comfort; minimal foreign body sensation: andunidirectional, specific release into the mucosal tissue. Otherpreferred characteristics for an effective and user-friendly product forthe treatment of mucosal surfaces include the use of pharmaceuticallyapproved components or materials; instantaneous adhesion to mucosalsurface upon application; increased residence time for the protection ofthe affected tissue or the delivery of the pharmaceutical component; andcase of removal of the delivery device from the affected tissue ornatural erosion of the delivery device at the delivery site.

Bioadhesive gels which are used for application to mucosal tissues andespecially the oral cavity are known in the art. For example, U.S. Pat.No. 5,192,802 describes a bioadhesive teething gel made from a blend ofsodium carboxymethyl cellulose and xanthan gum. The gel may also havepotential use in the treatment of canker sores, fever blisters, andhemorrhoids. However, this type of pharmaceutical carrier has a verylimited residence time, given that body fluids such as saliva quicklywash it away from the treatment site. Bioadhesive gels are alsodescribed in U.S. Pat. Nos. 5,314,915; 5,298,258; and 5,642,749. Thegels described in those patents use an aqueous or oily medium anddifferent types of bioadhesive and gelling agents.

Denture adhesive pastes are another type of bioadhesive product known inthe art. However, these preparations are used primarily for theiradhesive properties, to adhere dentures to the gums, rather than for theprotection of tissue or for the topical delivery of pharmaceuticals,although drugs such as local anesthetics may be used in the paste forthe relief of sore gums. U.S. Pat. Nos. 4,894,232 and 4,5 8,721 describedenture adhesive pastes. The '721 Patent describes a combination ofsodium carboxymethyl cellulose and polyethylene oxide in polyethyleneglycol.

Pastes have also been used as film protectants and as drug deliverysystems. One such example having film forming and adhesive properties isthe product commercialized under the name Orabase®-B, which is a thickgel or paste for the relief of mouth sores. Ingredients include guargum, sodium carboxymethyl cellulose, tragacanth gum, and pectin. Eventhough it does provide numbing to the area of application, the filmforming behavior and bioadhesion do not last. Thus, this product has alimited residence time.

Bioadhesive tablets are described in U.S. Pat. No. 4,915,948. Thewater-soluble bioadhesive material used in this device is a xanthan gumor a pectin combined with an adhesion enhancing material such as apolyol. Although residence time is improved with the use of bioadhesivetablets, they are not user friendly, especially when used in the oralcavity, given the unpleasant feelings associated with their solidity,bulkiness, and slow erosion time.

Bioadhesive tablets are also described in U.S. Pat. Nos. 4,226,848;4,292,299; and 4,250,163, and are single layer or bilayer devices havingan average thickness of 0.2 to 2.5 mm. The bioadhesive tablets describedin these patents utilize a non-adhesive component such as celluloseether, a bioadhesive component such as polyacrylic acid, sodiumcarboxymethyl cellulose, or polyvinylpyrrolidone, and a binder fortableting purposes. The cellulose derivatives may or may not bewater-erodable.

The use of bandages or bioadhesive laminated films, which are thinnerand flexible and therefore have a decreased foreign body sensation, isdescribed in U.S. Pat. Nos. 3,996,934 and 4,286,592. These products areused to deliver drugs through the skin or mucous. The laminated filmsusually include an adhesive layer, a reservoir layer, and a backinglayer. Bioadhesive devices designed to release drug through the skin ata given rate and over a period of time are usually not water soluble,and thus are not dissolved or washed away by bodily fluids.

In addition to film systems for the delivery of drug through the skin,film delivery systems for use on mucosal surfaces are also known. Thesetypes of systems, which are water-insoluble and usually in the form oflaminated, extruded or composite films, are described in U.S. Pat. Nos.4,517,173; 4,572,832; 4,713,243; 4,900,554; and 5,137,729. The '173Patent describes and claims a membrane-adhering film consisting of atleast three layers, including a pharmaceutical layer, a poor watersoluble layer, and an intermediate layer. The pharmaceutical layerincludes the drug and a cellulose derivative selected from hydroxypropylcellulose, methyl cellulose, and hydroxypropyl methyl cellulose. Thepoor water soluble layer is made by the combination of one or morecellulose derivatives with a poor water soluble fatty acid, and theintermediate layer is made of cellulose derivatives. The '832 Patentrelates to a soft film for buccal delivery, made by the combined use ofa water soluble protein, a polyol, and a polyhydric alcohol such ascellulose and polysaccharides, and also teaches the use of coloring orflavoring agents. The '243 Patent describes a single or multi-layeredbioadhesive thin film made from 40-95% water soluble hydroxypropylcellulose, 5-60% water-insoluble ethylene oxide, 0-10% water-insolubleethyl cellulose, propyl cellulose, polyethylene, or polypropylene, and amedicament. The films are three-layered laminates and include abioadhesive layer, a reservoir layer, and a non water-soluble outerprotective layer. The '729 Patent teaches a soft adhesive filmapplicable to the oral mucosa containing a systemic drug and comprisinga mixture of a vinyl acetate non water-soluble homopolymer, an acrylicacid polymer, and a cellulose derivative. Finally, the '554 Patentdescribes a device for use in the oral cavity having an adhesive layerincluding a mixture of an acrylic acid polymer, a water-insolublecellulose derivative, and a pharmaceutical preparation, and awater-insoluble or sparingly soluble backing layer. The adhesive layercontains the pharmaceutical, and upon application to the mucosalsurface, delivers the drug. The '554 Patent also states that “it isimpossible to achieve an adhesive device for application to body tissuewithout all three components, that is, acrylic acid polymer, waterinsoluble cellulose derivative and a water insoluble or sparinglysoluble backing layer.”

JP 56-100714 describes a preparation which comprises a coating layer andan active ingredient layer. The coating layer adheres to the mucosalmembrane and is comprised of a cellulose ether or an acrylic acidpolymer or salt. The active ingredient layer comprises an ointment basecomprised of water-insoluble substances such as fats and oils, waxes,hydrocarbons, higher fatty acids, higher alcohols, polyhydric alcoholsor glycerol esters. A surfactant and active ingredient are also presentin the active ingredient layer. Thus, the active ingredient is mixedwith an essentially non-water erodable substance. The previous examplesof thin films to be applied in the oral cavity by adhesion onto themucosal tissues all utilize polymers which are water-insoluble by natureor which are made water-insoluble by crosslinking, and claim a longresidence time. Therefore, unfortunately, the above examples of thinfilms do not provide a water erodable device with good adhesiveproperties. Therefore, upon release of the desired amount of drug, thethin films of water insoluble polymers must be peeled off the site ofapplication. Such peeling often removes tissue from the mucosal tissueand is painful to the patient. What is needed in the art is awater-erodable pharmaceutical delivery device which provides goodadhesion and localized delivery of a pharmaceutical with minimaldiscomfort to the patient.

SUMMARY OF THE INVENTION

The present invention relates to a novel water-erodable pharmaceuticalcarrier device for application to mucosal surfaces to provide protectionof and localized delivery of pharmaceutical to the site of application,surrounding tissues, and other bodily fluids such as blood or lymph,having an effective residence time, with minimal discomfort and ease ofuse. In one embodiment, the pharmaceutical delivery device includes alayered film disk which is water-erodable. The device comprises alayered film disk having an adhesive layer and a backing layer, bothwater-erodable, having the pharmaceutical in one or more of the layers.

In another embodiment, the pharmaceutical delivery device furthercomprises a third layer between the first adhesive layer and the secondbacking layer. The third layer is a water-erodable adhesive layer whichhas a surface area sufficient to encompass said first adhesive layer andcontact the mucosal surface. In this manner, localized delivery of apharmaceutical may be accomplished in a unidirectional manner toward themucosal layer.

The adhesive layer(s) comprise(s) a film-forming polymer such ashydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethylcellulose, hydroxyethyl methyl cellulose, polyvinyl alcohol,polyethylene glycol, polyethylene oxide, ethylene oxide-propylene oxideco-polymers, collagen and derivatives, gelatin, albumin, polyaminoacidsand derivatives, polyphosphazenes, polysaccharides and derivatives,chitin, or chitosan, alone or in combination and a bioadhesive polymersuch as polyacrylic acid, polyvinyl pyrrolidone, or sodium carboxymethylcellulose, alone or in combination.

The non-adhesive backing layer(s) comprise(s) hydroxyethyl cellulose,hydroxypropyl cellulose, hydroxyethylmethyl cellulose,hydroxypropylmethyl cellulose, polyvinyl alcohol, polyethylene glycol,polyethylene oxide, or ethylene oxide-propylene oxide co-polymers, aloneor in combination.

In another embodiment of the invention, one or more of the layers of thedevice further comprise a component which acts to adjust the kinetics ofthe erodability and provide a convenient manner of altering the releaseof the pharmaceutical and the lifespan of the device. A component whichacts to adjust the kinetics of the erodability is a water-based emulsionof a polylactide, polyglycolide, lactide-glycolide copolymers,poly-ε-caprolactone and derivatives, polyorthoesters and derivatives,polyanhydrides and derivatives, ethyl cellulose, vinyl acetate,cellulose acetate, and polyisobutylene, alone or in combination. Anothercomponent which acts to adjust the kinetics of the erodability isalkyl-glycol, propylene glycol, polyethyleneglycol, oleate, sebacate,stearate or esters of glycerol, or phthalate, alone or in combination.

In another embodiment of the invention, the number of layers of thedevice further may be varied to adjust the kinetics of the erodabilityand provide a convenient manner of altering the release of thepharmaceutical and the lifespan of the device.

In a preferred embodiment, the backing layer comprises two or morelayers with different erodibility kinetics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a three layered film disk wherein layers 2 and 3 arebioadhesive layers and layer 1 is a backing layer.

FIG. 2 is a three layered film disk wherein two of the layers arebioadhesive layers and the other layer is a backing layer. Thebioadhesive layer, layer 3, which will adhere to the mucosal tissue isof smaller surface area and encompassed by the second bioadhesive layer,layer 2, to provide unidirectional delivery. Layer 1 is a backing layer.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “water-erodable” means that the component,device, layer, etc. erodes in water-based media such as saliva, overtime. Such erosion in water may be due to factors such as dissolution,dispersion, friction, gravity, etc.

As used herein, the term “kinetics of erodability” or “erosion kinetics”refers to the timing of the release of pharmaceutical from the carrierdevice (release profile), as well as, the timing of the erosion of thedevice itself over time (lifespan or residence time of the device). Asdescribed herein, kinetics of erodability are based on factors such astype and amount of components in the device, thickness and number oflayers in the device, and additives or-excipients in the device. In acase in which all the components of the device are very water soluble,the kinetics of erodability will closely parallel the solubilitykinetics.

In the present invention, a novel water-erodable pharmaceutical devicewhich adheres to mucosal surfaces is provided. The present inventionfinds particular use in the localized treatment of body tissues,diseases, or wounds which may have moist surfaces and which aresusceptible to bodily fluids, such as the mouth, the vagina, or othertypes of mucosal surfaces. The device carries a pharmaceutical, and uponapplication and adherence to the mucosal surface, offers a layer ofprotection and delivers the pharmaceutical to the treatment site, thesurrounding tissues, and other bodily fluids. The device provides anappropriate residence time for effective drug delivery at the treatmentsite, given the control of erosion in aqueous solution or bodily fluidssuch as saliva, and the slow, natural erosion of the film concomitant orsubsequent to the delivery. In one embodiment, the pharmaceuticaldelivery device comprises a layered film disk having an adhesive layerand a backing layer, both water-erodable, having the pharmaceutical ineither or both layers.

Unlike bioadhesive gels and pastes known in the art, which have a verylimited residence time, given the tendency of bodily fluids such assaliva to wash away the gel from the treatment site, the presentinvention offers an increased residence time because of its filmyconsistency and components. A typical residence time for an aqueous gelor paste, such as Orajel®, Orabase®, or Kanka® is a few minutes. Thisshort residence time is a consequence of a limited or poor adhesion. Ina typical aqueous gel, the mucoadhesive components are either insolution, suspension, or swollen. Once applied to the mucosal surface,however, the water based gel does not instantaneously penetrate thelipophilic mucosal surface. The composition and water affinity of thesegels results in a tendency to quickly mix with the saliva, rapidlypulling away the different components of the gel, and limiting theresidence time. The same tendency is expected with pastes, the increasein viscosity only slightly delaying the timing. The present invention,by its solid form and its instantaneous adhesion to the mucosal surface,allows a lasting contact, a consequence of the entanglement of polymerchains and glycoproteins of the mucosal tissue which assures adhesion.Erosion kinetics in the saliva and other aqueous media are influenced bythe physical state of the device. While a gel or solution will readilymix with saliva and/or other bodily fluids, a solid form of the same orsimilar composition, such as the film of the present invention,dissolves/erodes more slowly.

Also, unlike the bioadhesive tablets which are known in the art, thepharmaceutical device of the present invention minimizes the discomfortassociated with application of a foreign substance for a period of timesufficient to provide effective drug delivery to the treatment site.Often, users of the bioadhesive tablets of the prior art experienceunpleasant sensations due to their solidity, bulkiness, and slowdissolution time if erodable, especially when used in the oral cavity.Moreover, the typical thickness of bioadhesive tablets, which may or maynot be water soluble, is a couple of millimeters, and because of theirthickness, the preferred site of application is on the upper gingivalarea. This site is usually unsatisfactory for local delivery as the typeof compounds to be delivered, their bioavailability, and pharmokineticsis limited. In contrast to tablets, the device of the present inventionoffers the advantages of an effective residence time with minimaldiscomfort and ease of use, and is an appropriate vehicle for the local,as well as systemic, delivery of pharmaceutical, given its thinner,flexible form.

Finally, unlike the film systems known in the art which are used todeliver pharmaceutical through the skin or mucous, the device of thepresent invention is made of water-erodable components and thus isbioerodable. The use of water-erodable components allows the device toerode over a period of time, with natural bodily fluids slowlydissolving or eroding away the carrier, while the pharmaceutical remainsat the application site. Unlike bandages and other non-water-erodablefilm systems, the user of the present invention does not have to removethe device following treatment. Nor does the user experience thesensation of the presence of a foreign object at the mucosal surface orwithin the body cavity, given that upon application, water absorptionsoftens the device, and over time, the device slowly dissolves or erodesaway.

The residence time of the device of the present invention depends on theerosion rate of the water-erodable polymers used in the formulation andtheir respective concentrations. The erosion rate may be adjusted, forexample, by mixing together components with different solubilitycharacteristics or chemically different polymers, such as hydroxyethylcellulose and hydroxypropyl cellulose; by using different molecularweight grades of the same polymer, such as mixing low and mediummolecular weight hydroxyethyl cellulose; by using excipients orplasticizers of various lipophilic values or water solubilitycharacteristics (including essentially insoluble components); by usingwater soluble organic and inorganic salts; by using crosslinking agentssuch as glyoxal with polymers such as hydroxyethyl cellulose for partialcrosslinking; or by post-treatment irradiation or curing, which mayalter the physical state of the film, including its crystallinity orphase transition, once obtained. These strategies might be employedalone or in combination in order to modify the erosion kinetics of thedevice.

Upon application, the pharmaceutical delivery device adheres to themucosal surface and is held in place. Water absorption softens thedevice, thereby diminishing the foreign body sensation. As the devicerests on the mucosal surface, delivery of the drug occurs. Residencetimes may be adjusted over a wide range depending upon the desiredtiming of the delivery of the chosen pharmaceutical and the desiredlifespan of the carrier. Generally, however, the residence time ismodulated between about a few seconds to about a few days. Preferably,the residence time for most pharmaceuticals is adjusted from about 30minutes to about 24 hours. More preferably, the residence time isadjusted from about 1 hour to about 8 hours. In addition to providingdrug delivery, once the device adheres to the mucosal surface, it alsoprovides protection to the treatment site, acting as an erodablebandage.

In one embodiment, the present invention comprises a film disc having anadhesive layer and a non-adhesive backing layer which can be comprisedof components having a similar or different hydrophilicity. Thepharmaceutical component may be included in either layer, althoughpreferably, it is included in the adhesive layer, which is closest tothe treatment site and which will have a slower erosion time, given thatthe backing layer protects the interior, adhesive layer and willtypically erode first.

The adhesive layer may comprise at least one film-forming water-erodablepolymer (the “film-forming polymer”) and at least one pharmacologicallyacceptable polymer known for its bioadhesive capabilities (the“bioadhesive polymer”). The film forming polymer may comprisehydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethylcellulose, hydroxyethyl methyl cellulose, polyvinyl alcohol,polyethylene glycol, polyethylene oxide, ethylene oxide-propylene oxideco-polymers, collagen and derivatives, gelatin, albumin, polyaminoacidsand derivatives, polyphosphazenes, polysaccharides and derivatives,chitin and chitosan, alone or in combination. Preferably, thefilm-forming polymer comprises hydroxyethyl cellulose and hydroxypropylcellulose. Preferably, in the case of hydroxyethyl cellulose, theaverage molecular weight (Mw estimated from intrinsic viscositymeasurements) is in the range 10² to 10⁶ and more preferably in therange 10³ to 10 ^(5,) while in the case of hydroxypropyl cellulose, theaverage molecular weight (Mw obtained from size exclusion chromatographymeasurements) is in the range 50×10³ to 1.5×10⁶, and more preferablybetween 80×10³ to 5×10⁵.

The bioadhesive polymer of the adhesive layer may comprise polyacrylicacid (PAA), which may or may not be partially crosslinked, sodiumcarboxymethyl cellulose (NaCMC), and polyvinylpyrrolidone (PVP), orcombinations thereof. These bioadhesive polymers are preferred becausethey have good and instantaneous mucoadhesive properties in a dry, filmstate. In the case of sodium carboxymethyl cellulose, typical averagemolecular weights comprise 50,000 to 700,000, and preferably 60,000 to500,000, with a degree of substitution of 0.7. The substitution rangevaries between 0.5 and 1.5, and preferably between 0.6 and 0.9. Thepolyvinyl pyrrolidone can be characterized according to its averagemolecular weight and comprises between 5,000 and 150,000, preferablybetween 10,000 and 100,000. The simultaneous use of PAA with some gradesof PVP may result in the precipitation of one or both components. Thisprecipitation may not be ideal to obtain a homogenous layer and mayslightly alter the overall adhesive properties of the device.

While not wishing to bound to a particular theory, it is believed thatthe adhesion properties of the present invention are the result of theentanglement of polymer chains and interactions with glycoproteins ofthe mucosal surface. The chemical nature of the bioadhesive polymers,including chain and side groups and crosslinking agents, generatesinteractions between the mucosal constituents and the polymer orpolymers, such as physical entanglement, Van der Wards interactions, andhydrogen bonding. Given that the composition of mucosal tissues differsfrom one individual to another and changes naturally over time, the useof a combination of bioadhesive polymers or the use of a combination ofdifferent grades of the same polymer is preferred. The use of acombination of at least two bioadhesive polymers maximizes the adhesioncapabilities of the device, although use of a single bioadhesive polymeris effective as well.

The ratio of the bioadhesive polymer to the film-forming polymer in theadhesive layer may vary, depending on the type of pharmaceutical and theamount of pharmaceutical to be used. However, the content of combinedcomponents in the adhesive layer is usually between 5 and 95% by weight,preferably between 10 and 80% by weight. In terms of weight percent ofthe different bioadhesive polymers PAA, NaCMC, and PVP, some examplesare provided below and using the examples one skilled in the art will beable to readily adjust the percentages to obtain a pharmaceutical devicehaving desired characteristics for a given application. Preferredcombinations include PAA and NaCMC, NaCMC and PVP, or PAA and PVP, andalso include the use of different grades of the same polymer.

The non adhesive backing layer may comprise a water-erodable,film-forming pharmaceutically acceptable polymer such as hydroxyethylcellulose, hydroxypropyl cellulose, hydroxypropylmethyl cellulose,hydroxyethylmethyl cellulose, polyvinyl alcohol, polyethylene glycol,polyethylene oxide, ethylene oxide-propylene oxide copolymers, collagenand derivatives, gelatin, albumin, polyaminoacids and derivatives,polyphosphazenes, polysaccharides and derivatives, chitin and chitosan,alone or in combination. The backing layer component may or may not becrosslinked depending on the desired erosion kinetics. In oneembodiment, the preferred backing layer component comprises hydroxyethylcellulose or hydroxypropyl cellulose, and more preferably compriseshydroxyethyl cellulose. Preferably, in the case of hydroxyethylcellulose, the average molecular weight (Mw estimated from intrinsicviscosity measurements) is in the range 10² to 10⁶, and more preferablyin the range 10³ to 10⁵, while in the case of hydroxypropyl cellulose,the average molecular weight (Mw obtained from size exclusionchromatography measurements) is in the range of 50×10³ to 1.5×10⁶ andmore preferably from 80×10³ to 5×10⁵.

Moreover, it has been discovered that a particularly preferablecombination for the backing layer comprises hydroxypropyl cellulose andan alkylcellulose such as methylcellulose or ethylcellulose. Such acombination comprises a film-forming amount of alkylcellulose,hydroxypropyl cellulose, and a suitable solvent. Advantageously, thecharacteristics of the film formed from the gel may be modifieddepending upon the ratio of hydroxypropyl cellulose to alkylcellulose.Such modifiable characteristics advantageously include the kinetics oferodability.

Typically, the ratio of hydroxypropyl cellulose to alkylcellulose isthat necessary to form a suitable film. This ratio may vary based on theother components and the type of alkylcellulose. However, ifethylcellulose is employed then the ratio of hydroxypropyl cellulose toethyl cellulose is usually from about 1000:1 to about 3:1, preferablyfrom about 200:1 to about 4:1, more preferably from about 200:1 to about8:1. Typically, as the ratio of hydroxypropyl cellulose toalkylcellulose increases, the water erodability increases, i.e., thefilms are more readily washed away. Thus, the ethylcellulose is acomponent which acts to adjust the kinetics of erodability of thedevice.

As described above, the erosion kinetics of one or more of the layers(adhesive layer, backing layer, or both) may be altered in manydifferent ways in order to modify the residence time and the releaseprofile of a drug. One way is by crosslinking or plasticizing thefilm-forming polymer. Crosslinking agents known in the art areappropriate for use in the invention and may include glyoxal, propyleneglycol, glycerol, dihydroxy-polyethylene glycol of different sizes,butylene glycol, and combinations thereof. The amount of crosslinkingagent used may vary, depending on the particular polymers andcrosslinking agent but usually should not exceed 5% molar equivalent ofthe polymeric material, and preferably comprises 0 to 3% molarequivalent of the polymeric material.

Another way of altering the residence time and release profile is byemploying a component in one or more of the layers which acts to adjustthe kinetics of the erodability of the layer. While these componentswill vary widely depending upon the particular pharmaceutical deliverydevice employed, preferred components include water-based emulsions ofpolylactide, polyglycolide, lactide-glycolide copolymers,poly-ε-caprolactone and derivatives, polyorthoesters and derivatives,polyanhydrides and derivatives, ethyl cellulose, vinyl acetate,cellulose acetate, silicone, polyisobutylene and derivatives, alone orin combination.

It is also possible to adjust the kinetics of erodability of the devicesby adding excipients which are very soluble in water such as watersoluble organic and inorganic salts. Suitable such excipients mayinclude the sodium and potassium salts of chloride, carbonate,bicarbonate, citrate, trifluoroacetate, benzoate, phosphate, fluoride,sulfate, or tartrate. The amount added will vary depending upon how muchthe erosion kinetics are to be altered as well as the amount and natureof the other components in the device.

Emulsifiers typically used in the water-based emulsions described aboveare, preferably, either obtained in situ if selected from the linoleic,palmitic, myristoleic, lauric, stearic, cetoleic or oleic acids andsodium or potassium hydroxide, or selected from the laurate, palmitate,stearate, or oleate esters of sorbitol and sorbitol anhydrides,polyoxyethylene derivatives including monooleate, monostearate,monopalmitate, monolaurate, fatty alcohols, alkyl phenols, alyl ethers,alkyl aryl ethers, sorbitan monostearate, sorbitan monooleate andsorbitan monopalmitate.

Furthermore, in the case of the water-insoluble polymeric materials suchas the polyesteraliphatic family (co-polymers of lactide-glycolide,caprolactone, etc.) the average molecular weight (Mw) is in the range10² to 10⁵ and, more preferably, 10³ to 10⁴, while in the case of thecellulosic family (ethyl cellulose, cellulose acetate, etc.), theaverage molecular weight (Mw estimated from intrinsic viscositymeasurements) is in the range 10² to 10⁶ and more preferably in therange 10³ to 10⁵.

Yet another manner of modifying the erosion kinetics of any layer, is byemploying excipients which plasticize the film concomitantly. Theexcipient or plasticizer often improves the mechanical properties of thedevice and/or modifies the drug release profile or disintegation time.Suitable excipients or plasticizers modifying the erosion behavior ofthe layer(s) may include alkyl-glycol such as propylene glycol,polyethyleneglycols, oleate, sebacate, stearate or esters of glycerol,phthalate and others. Other suitable plasticizers include esters such asacetyl citrate, amyl oleate, myristyl acetate, butyl oleate andstearate, dibutyl sebacate, phthalate esters such as diethyl, dibutyl,and diethoxy ethyl phthalate and the like, fatty acids such as oleic andstearic acid, fatty alcohols such as cetyl, myristyl, and stearylalcohol. Moreover, in some instances, a polymer, a pharmaceutical, orsolvent residual may act as a plasticizer.

It is also possible to modify the erosion kinetics of the device of theinstant invention by adjusting the thickness and number of layers.Typically, the thicker the layers, the slower the release ofpharmaceutical and the longer the release profile. Correspondingly, themore layers there are, the slower the release of pharmaceutical and thelonger the release profile. In a preferred embodiment, the backing layercomprises two or more layers with different erosion kinetics.

Moreover, combinations of different polymers or similar polymers withdefinite molecular weight characteristics may be used in order toachieve preferred film forming capabilities, mechanical properties, andkinetics of dissolution in any layer. Some combinations for use in theinvention are provided in the examples below and may include ¾ ofhydroxyethyl cellulose and ¼ of hydroxypropyl cellulose; ⅘ of lowmolecular weight hydroxyethyl cellulose and ⅕ of medium molecular weighthydroxyethyl cellulose; and 8/9 of low molecular weight hydroxyethylcellulose and 1/9 of high molecular weight hydroxyethyl cellulose. Asmentioned previously, combinations of water-erodable polymers may beemployed in order to modify the erosion kinetics of the device. Aparticularly preferred combination includes ½ hydroxyethyl cellulose, ⅙hydroxypropylcellulose, and 2/6 of a pseudolatex, i.e. emulsion ofpolymer, of lactide-glycolide copolymer.

The pharmaceutical component of the present invention may comprise asingle pharmaceutical or a combination of pharmaceuticals, which may beincorporated in the adhesive layer, the backing layer, or both.Pharmaceuticals which may be used, either alone or in combination,include anti-inflammatory analgesic agents, steroidal anti-inflammatoryagents, antihistamines, local anesthetics, bactericides anddisinfectants, vasoconstrictors, hemostatics, chemotherapeutic drugs,antibiotics, keratolytics, cauterizing agents, antiviral drugs,antirheumatics, antihypertensives, bronchodilators, anticholinergics,antimenimic compounds, hormones and macromolecules, peptides, proteinsand vaccines.

Examples of anti-inflammatory analgesic agents include acetaminophen,methyl salicylate, monoglycol salicylate, aspirin, mefenamic acid,flufenamic acid, indomethacin, diclofenac, alclofenac, diclofenacsodium, ibuprofen, ketoprofen, naproxen, pranoprofen, fenoprofen,sulindac, fenclofenac, clidanac, flurbiprofen, fentiazac, bufexamac,piroxicam, phenylbutazone, oxyphenbutazone, clofezone, pentazocine,mepirizole, tiaramide hydrochloride, etc. Examples of steroidalanti-inflammatory agents include hydrocortisone, predonisolone,dexamethasone, triamcinolone acetonide, fluocinolone acetonide,hydrocortisone acetate, predonisolone acetate, methylpredonisolone,dexamethasone acetate, betamethasone, betamethasone valerate,flumetasone, fluorometholone, beclomethasone diproprionate,fluocinonide, etc.

Examples of antihistamines include diphenhydramine hydrochloride,diphenhydramine salicylate, diphenhydramine, chlorpheniraminehydrochloride, chlorpheniramine maleate isothipendyl hydrochloride,tripelennamine hydrochloride, promethazine hydrochloride, methdilazinehydrochloride, etc. Examples of local anesthetics include dibucainehydrochloride, dibucaine, lidocaine hydrochloride, lidocaine,benzocaine, p-buthylaminobenzoic acid 2-(die-ethylamino) ethyl esterhydrochloride, procaine hydrochloride, tetracaine, tetracainehydrochloride, chloroprocaine hydrochloride, oxyprocaine hydrochloride,mepivacaine, cocaine hydrochloride, piperocaine hydrochloride,dyclonine, dyclonine hydrochloride, etc.

Examples of bactericides and disinfectants include thimerosal, phenol,thymol, benzalkonium chloride, benzethonium chloride, chlorhexidine,povidone iode, cetylpyridinium chloride, eugenol, trimethylammoniumbromide, etc. Examples of vasoconstrictors include naphazoline nitrate,tetrahydrozoline hydrochloride, oxymetazolinc hydrochloride,phenylephrine hydrochloride, tramazoline hydrochloride, etc. Examples ofhemostatics include thrombin, phytonadione, protamine sulfate,aminocaproic acid, tranexamic acid, carhazochrome, carbaxochrome sodiumsulfanate, rutin, hesperidin, etc.

Examples of chemotherapeutic drugs include sulfamine, sulfathiazole,sulfadiazine, homosulfamine, sulfisoxazole, sulfisomidine,sulfamethizole nitrofurazone, etc. Examples of antibiotics includepenicillin, meticillin, oxacillin, cefalotin, cefalordin, crythromcycin,lincomycin, tetracycline, chlortetracycline, oxytetracycline,metacycline, chloramphenicol, kanamycin, streptomycin, gentamicin,bacitracin, cycloserine, etc.

Examples of keratelytics include salicylic acid, podophyllum resin,podolifox, and cantharidin. Examples of cauterizing agents include thechloroacetic acids and silver nitrate. Examples of antiviral drugsinclude protease inhibitors, thymadine kinase inhibitors, sugar orglycoprotein synthesis inhibitors, structural protein synthesisinhibitors, attachment and adsorption inhibitors, and nucleosideanalogues such as acyclovir, penciclovir, valacyclovir, and gauciclovir.

Examples of proteins, peptides, vaccines, genes and the like includeheparin, insulin, LHRH, TRH, interferons, oligonuclides, calcitonin, andoctreotide.

Other pharmaceuticals which may be employed include omeprazone,fluoxetine, ethinylestradiol, amiodipine, paroxetine, enalapril,lisinopril, leuprolide, prevastatin, lovastatin, norethindrone,risperidone, olanzapine, albuterol, hydrochlorothiazide,pseudoephridrine, warfarin, terazosin, cisapride, ipratropium,busprione, methylphenidate, levothyroxine, zolpidem, levonorgestrel,glyburide, benazepril, medroxyprogesterone, clonazepam, ondansetron,losartan, quinapril, nitroglycerin, midazolam versed, cetirizine,doxazosin, glipizide, vaccine hepatitis B, salmeterol, sumatriptan,triamcinolone acetonide, goserelin, beclomethasone, granisteron,desogestrel, alprazolam, estradiol, nicotine, interferon beta 1A,cromolyn, fosinopril, digoxin, fluticasone, bisoprolol, calcitril,captorpril, butorphanol, clonidine, premarin, testosterone, sumatriptan,clotrimazole, bisacodyl, dextromethorphan, nitroglycerine In D,nafarelin, dinoprostone, nicotine, bisacodyl, goserelin, andgranisetron.

The amount of active pharmaceutical(s) to be used depends on the desiredtreatment strength and the composition of the layers, althoughpreferably, the pharmaceutical component comprises from about 0.001 toabout 99, more preferably from about 0.003 to about 30, and mostpreferably from about 0.005 to about 20% by weight of the device.

Plasticizers, flavoring and coloring agents, and preservatives may alsobe included in the pharmaceutical delivery device of the presentinvention in the adhesive layer, the backing layer, or both. The amountsof each may vary depending on the drug or other components but typicallythese components comprise no more than 50, preferably no more than 30,most preferably no more than 15% by total weight of the device.

A permeation enhancer may be added to the device to improve absorptionof the drug. Typically, such a permeation enhancer is added to the layerin which the pharmaceutical is to be contained. Suitable permeationenhancers include natural or synthetic bile salts such as sodiumfusidate; glycocholate or deoxycholate; fatty acids and derivatives suchas sodium laurate, oleic acid, oleyl alcohol, monoolein, andpalmitoylcarnitine; chelators such as disodium EDTA, sodium citrate andsodium laurylsulfate, azone, sodium cholate, sodium 5-methoxysalicylate,sorbitan laurate, glyceryl monolaurate, octoxynonyl-9, laureth-9,polysorbates, etc.

The thickness of the device may vary, depending on the thickness of eachof the layers and the number of layers. As stated above, both thethickness and amount of layers may be adjusted in order to vary theerosion kinetics. Preferably, if the device has only two layers, thethickness ranges from 0.05 mm to 3 mm, preferably from 0.1 to 1 mm, andmore preferably from 0.1 to 0.5 mm. The thickness of each layer may varyfrom 10 to 90% of the overall thickness of the layered device, andpreferably varies from 30 to 60%. Thus, the preferred thickness of eachlayer may vary from 0.01 mm to 0.9 mm, and more preferably from 0.03 to0.6 mm.

While the device of the invention only requires two layers, i.e., anadhesive layer and a backing layer, it is often preferable to haveadditional layers. One instance in which this might be advantageous iswhen specific unidirectional flow of a pharmaceutical is required towarda mucosal layer. The layered device described above provides somedirectional release, i.e., release will mainly be toward the mucosa andnot, for instance, into the oral or vaginal cavity. However, due to theswelling characteristics of the thin film, a small amount ofpharmaceutical may also be released through the sides of the device andthe backing layer if all the layers are of the approximately the samesurface area and are essentially on top of one another. While apreferential, but not specific, release is acceptable, and evendesirable, for many pharmaceuticals, other pharmaceuticals may requireunidirectional, specific release into the mucosal tissue.

An example of when unidirectional release may be desirable is when thepharmaceutical to be delivered has a specific therapeutic window or hasundesirable side effects it absorbed in the gastrointestinal tract.Furthermore, some pharmaceuticals arc enzymatically degraded. Therefore,a bioerodible mucoadhesive system allowing a transmucosal unidirectionaldelivery and protecting the drug being delivered from enzymes present,for instance, in the oral or vaginal cavities would have advantages.

In such instances when unidirectional release is desired, an additionallayer may be placed between the first adhesive layer and the secondbacking layer. The third layer is a water-erodable adhesive layer whichhas a surface area sufficient to encompass said first adhesive layer andcontact the mucosal surface. The third layer may be comprised of any ofthe components described above for the first adhesive layer and thus maybe the same or different than the first adhesive layer. FIG. 2illustrates a disk having a third layer which encompasses the firstadhesive layer.

If a bioadhesive layer is to be of a smaller surface area than the otherlayers then it is usually between about 5 and about 50, preferablybetween about 10 and about 30% smaller than the other layers.

in the aforementioned manner, localized delivery of a pharmaceutical maybe accomplished in a unidirectional manner. For instance, ifpharmaceutical is present in the first adhesive layer then it isprevented from being released through the sides and back of the device.If pharmaceutical is present in the backing layer, then it is preventedfrom entering the mucosal layer to which the device is adhered.Likewise, if a pharmaceutical is present in the first adhesive layer andthe backing layer, they are prevented from mixing.

The pharmaceutical delivery device of the present invention may beprepared by numerous methods known in the art. In one embodiment, thecomponents are dissolved in a biocompatible solvent, preferably anaqueous medium or a combination of water and lower alkanols, to preparea solution, a gel, or a suspension that can be used for coating.Solvents for use in the present invention may comprise water, methanol,ethanol, propanol, or low alkyl alcohols such as isopropyl alcohol, oracetone. Other suitable solvents may comprise dimethyl acetamide,N-methyl-2-pyrrolidone, dimethyl sulfoxide, ethoxydiglycol, propyleneglycol, polyethylene glycol. The final solvent content or residualsolvent content in the film may be the result of either or both layers.Typically, such final solvent content is at least about 10, preferablyat least about 5, more preferably at least about 1% by weight of thetotal device. Similarly, the final solvent content is not more thanabout 20, preferably not more than about 15, most preferably not morethan about 10% by weight of the total device. The solvent may also beused as a plasticizer or an erosion rate-modifying agent.

Each solution is then coated onto a substrate. Eventually, one of thecomponents might be in suspension. Each solution is casted and processedinto a thin film by techniques known in the art, such as by filmdipping, film coating, film casting, spin coating, or spray drying usingthe appropriate substrate. The thin film is then allowed to dry. Ifdesired, the drying step can be accomplished in any type of oven inorder to facilitate the process. However, as one skilled in the art willappreciate, the solvent residual, which may effect the erosion kinetics,depends on the drying procedure. The film layers may be filmedindependently and then laminated together or may be filmed one on thetop of the other.

The film obtained after the two layers have been laminated together orcoated on top of each other may be cut, if desired, into any type ofshape which is suitable for application to the mucosal tissue. Suitableshapes may include disks, ellipses, squares, rectangles, parallepipedes,as well as, shredded, meshed, or porous films depending upon the purposeand location where the device is to be employed. Likewise, the surfacearea of the device of the present invention will necessarily varydepending on many factors with the major factor being where the deviceis to be employed. Typically, the surface area may be from about 0.1 toabout 30, preferably from 0.5 to about 20 square centimeters.

Methods for treating mucosal surfaces, surrounding tissues, and bodilyfluids for localized and systemic drug delivery are also provided. Inone embodiment, the method comprises applying an adherent film of theinvention to the treatment site in order to provide protection to thetreatment site and drug delivery. The adherent film may comprise any ofthe layered devices provided herein. In a preferred embodiment, themethod comprises application of a layered pharmaceutical carrier devicehaving a first adhesive layer and a second non-adhesive backing layer asdescribed above, each layer having a thickness of from 0.01 mm to 0.9mm. The pharmaceutical or combination of pharmaceuticals may be presentin the adhesive layer, the non-adhesive backing layer, or both layers.

As one skilled in the art will appreciate, when systemic delivery, e.g.,transmucosal or transdermal delivery, is desired the treatment site mayinclude any area in which the adherent film of the invention is capableof maintaining a desired level of pharmaceutical in the blood, lymph, orother bodily fluid. Typically, such treatment sites include the oral,anal, nasal, and vaginal mucosal tissue, as well as, the skin. If theskin is to be employed as the treatment site, then usually larger areasof the skin wherein movement will not disrupt the adhesion of thedevice, such as the upper arm or thigh, are preferred.

While the pharmaceutical carrier described in this application readilyadheres to mucosal tissues, which are wet tissues by nature, it can alsobe used on other surfaces such as skin or wounds. The water-soluble filmof the present invention will adhere to the skin if prior to applicationthe skin is wet with an aqueous-based fluid such as water, saliva, orperspiration. The film will typically adhere to the skin until it erodesdue contact with water by, for example, showering, bathing or washing.The film may also be readily removed by peeling without significantdamage to tissue.

While it is in contact with the skin, the film may act as a washable,erodable bandage to protect the area where it has been applied. It isalso possible to employ the film as a transdermal drug delivery systemto facilitate the healing process and keep the wound or burn free ofgerms and debris. A significant advantage of the instant invention overconventional alternatives is that not only is the film washable, butalso, perspiration helps the adhesion of the device instead ofpreventing or reducing it as with conventional transdermal patches.

The pharmaceutical carrier of the present invention can also be used asa wound dressing. By offering a physical, compatible, oxygen andmoisture permeable, flexible barrier which can be washed away, the filmcan not only protect a wound but also deliver a pharmaceutical in orderto promote healing, asepty, scarification, to ease the pain or toimprove globally the condition of the sufferer. Some of the examplesgiven below are well suited for an application to the skin or a wound.As one skilled in the art will appreciate, the formulation might requireincorporating a specific hydrophilic/hygroscopic excipient which wouldhelp in maintaining good adhesion on dry skin over an extended period oftime. Another advantage of the present invention when utilized in thismanner is that if one does not wish that the film be noticeable on theskin, then no dyes or colored substances need be used. If on the otherhand, one desires that the film be noticeable, a dye or coloredsubstance may be employed.

The following examples are provided to illustrate pharmaceutical carrierdevices, as well as, methods of making and using pharmaceutical carrierdevices of the present invention.

EXAMPLE 1

A 100 ml solution for the non-adhesive backing layer was made using87.98% by weight water USP, 0.02% by weight FD&C red 40 dye, and 12% byweight hydroxyethyl cellulose (Mw 9×10⁴). Using a Werner MathisLabcoater, the substrate (Mylar 1000D or other polyester films such as3M ScotchPak 1022) was set. 90 ml of the backing layer solution was setin front of a knife over roll with an opening of 1.5 mm. The solutionwas then casted and the film dried for 8-9 min. at 60° C. Following thedrying step, a 0.14 mm thick reddish film was the result.

Using this procedure, the film may be easily peeled off the substrateafter drying, or may be left on the substrate and rolled, to belaminated later, or for use as a substrate for the adhesive layer.

EXAMPLE 2

A 100 ml solution for the non-adhesive backing layer was made using94.98% by weight water USP, 0.02% by weight FD&C red 40 dye, and 5% byweight hydroxypropyl cellulose. The procedure of example 1 was used,resulting in a 0.16 mm thick film.

EXAMPLE 3

A 100 ml solution for the non-adhesive backing layer was made using84.98% by weight water USP, 0.02% by weight FD&C red 40 dye, 12% byweight hydroxyethyl cellulose, and 3% by weight hydroxypropyl cellulose.Here, the overall polymeric material was at a 15% concentration insolution. The mixture of two different types of polymeric materialsmodified the overall mechanical properties and erosion kineticscharacteristics of the backing film. The solution was then casted on apolyester substrate and dried overnight at 90° C. The opening of theknife was set at 3 mm, resulting in a 0.3 mm thick film.

EXAMPLE 4

A 100 ml solution for the non-adhesive backing layer was made using87.98% by weight water USP, 0.02% by weight FD&C red 40 dye, 10% byweight hydroxyethyl cellulose (Mw 9×10⁴), and 2% by weight hydroxyethylcellulose (Mw 7×10⁵). Here, the mixture of two different types ofhydroxyethyl cellulose modified the mechanical properties and erosionkinetics of the backing film. The solution was then cast on a polyestersubstrate and dried for 12 min. at 135° C. The opening of the knife wasset at 3 mm, resulting in a 0.27 mm thick film.

EXAMPLE 5

A 100 ml solution for the non-adhesive backing layer was made using87.98% by weight water USP, 0.02% by weight FD&C red 40 dye, 11.75% byweight hydroxyethyl cellulose (Mw 9×10⁴), and 0.25% by weighthydroxyethyl cellulose (Mw 1.3×10⁶). The procedure of Example 1 wasused, resulting in a 0.14 mm thick film.

Here, the mixture of two different grades of hydroxyethyl cellulosemodified the mechanical properties and erosion kinetics of the backingfilm. The ratio may be used to adjust the erosion pattern and residencetime of the bioadhesive disk. Compared to the backing layer of Example1, which was made of 12% by weight hydroxycthyl cellulose (Mw 9×10⁴),and which had an erosion time of about 21 minutes (See Table 2), thebacking layer of this Example, made from a combination of two grades ofhydroxyethyl cellulose, had an erosion time of about 69 minutes (SeeTable 2).

EXAMPLE 6

A 100 ml solution for the non-adhesive backing layer was made using87.98% by weight water USP. 0.02% by weight FD&C red 40 dye, 11.95% byweight hydroxyethyl cellulose (Mw 9×10⁴), and 0.05% by weight of 40%glyoxal aqueous solution. The procedure of Example 1 was used, resultingin a 0.13 mm film.

Here, the glyoxal acted as a crosslinking agent, inducing a slow down inthe erosion kinetics of the backing film. Compared to the backing layerof Example 1, which had no glyoxal and which had an erosion time ofabout 21 minutes (See Table 2), the backing layer of this Example, whichincorporated glyoxal, had an erosion time of about 57 minutes (See Table2).

EXAMPLE 7

A 100 ml solution for the non-adhesive backing layer was made using87.98% by weight water USP, 0.02% by weight FD&C red 40 dye, 11.8% byweight hydroxyethyl cellulose, 0.1% by weight of 40% glyoxal aqueoussolution, and 0.1% sweet peppermint flavor. Here, as in Example 6, theglyoxal acted as a crosslinking agent, inducing a slow down in theerosion kinetics of the backing film, compared with a backing layer withno glyoxal. The sweet peppermint was added as a flavoring agent.

EXAMPLE 8

As described in Example 1, the solutions of Examples 5, 6 and 7 wereeach casted on a polyester substrate. Instead of using a knife, ameier's bar was used to coat the substrate. The films were driedovernight at 90° C. The dried films were thicker, having a thickness ofabout 0.17 mm.

EXAMPLE 9

The solution of Example 1 was prepared in a beaker. A microslide wasthen dipped quickly into the solution until it was fully immersed,removed from the solution, and left at room temperature for about 1hour. The microslide was then dried overnight at 90° C. The resultingfilm was heterogeneous and had an average thickness of about 0.2 mm.

EXAMPLE 10

A 100 ml solution for the non-adhesive backing layer was made using 84%by weight water USP, 0.02% by weight FD&C red 40 dye, 11% by weighthydroxyethyl cellulose (Mw 9×10⁴), 1% by weight hydroxyethyl cellulose(Mw 7×10), 0.1% by weight of a 40% glyoxal aqueous solution, 3% byweight glyoxal, and 1% by weight menthol. Here, the glyoxal acted as acrosslinking agent, inducing a slow down in the erosion kinetics of thebacking film. Also, the mixture of two different grades of hydroxyethylcellulose was used to achieve slow release of the menthol. The film wascoated on a polyester film as previously described.

EXAMPLE 11

A 100 ml solution for the adhesive layer was made using 88.6% by weightwater USP, 1.8% by weight hydroxyethyl cellulose, Natrosol® 99-250 L NF(Aqualon), 2.6% by weight polyacrylic acid, Noveon® AA 1 USP (BFGoodrich), 4.5% sodium carboxymethyl cellulose, cellulose gum 7 LF PH(Aqualon), and 2.5% by weight dyclonine HCl. Upon mixing, a suspensionwas formed.

Here, dyclonine HCl may be easily substituted with any other activepharmaceutical component. However, chemical characteristics of theactive pharmaceutical, such as solubility, counter ions, and meltingpoint, might require minor modifications of the overall process, such asdissolution in a particular solvent, changing the temperature of thesolution, etc. The next example illustrates one slight modification.

EXAMPLE 12

A 100 ml solution for the adhesive layer was made using 74.6% by weightwater USP, 1.8% by weight hydroxyethyl cellulose, 2.6% by weightpolyacrylic acid, 4.5% sodium carboxymethyl cellulose, 2.5% by weightbenzocaine, and 14% by weight ethyl alcohol. The use of benzocaine asthe active pharmaceutical required that it first be dissolved in ethylalcohol, given that benzocaine is more soluble in alcohol than water.

In the final solution, the benzocaine tends to precipitate in the formof a very fine powder. However, the film characteristics and bioadhesiveproperties remain intact.

EXAMPLE 13

A 100 ml solution for the adhesive layer was made using 91% by weightwater USP, 2% by weight hydroxyethyl cellulose, 2.5% by weightpolyacrylic acid, and 4.5% sodium carboxymethyl cellulose. Thecomposition of the adhesive layer may be modified and may vary accordingthe ranges described in Table 1 below:

TABLE 1 Item # % w Material 1    60 to 99.5 Water USP 2 0.05 to 5 Hydroxyethyl cellulose 3 0.5 to 10 Polyacrylic acid 4 0.0 to 15 SodiumCarboxymethyl cellulose 5  −0 to 10 Polyvinyl pyrrolidone

The relative part of each components depends of the chemicalcompatibility of the components and the residence time to be obtained.

EXAMPLE 14

A 100 ml solution for the adhesive layer was made using 90% by weightwater USP, 1% by weight butacaine sulfate, 2% by weight hydroxyethylcellulose, 2.5% by weight polyvinyl pyrrolidone, and 4.5% by weightsodium carboxymethyl cellulose. The solution was coated using a knifeover roll on a Mylar substrate.

EXAMPLE 15

A 100 ml solution for the adhesive layer was made. The total compositionof the solution was 48.6% water, 40% ethyl alcohol, 1.8% hydroxyethylcellulose, 2.6% polyacrylic acid, 4.5% sodium carboxymethyl cellulose,and 2.5% dyclonine HCl. Here, however, the dyclonine HCl was firstsolubilized in 40 ml ethyl alcohol, and then, 48.6 ml of water wereadded to the dyclonine HCl/ethyl alcohol solution, followed by theaddition of the other components.

The use of ethyl alcohol as an additional solvent resulted in asuspension which was slightly more viscous than that of Example 11,which used water as the only solvent.

EXAMPLE 16

Following the procedure of Example 12, a 100 ml solution for theadhesive layer was prepared. The solution was then coated following theprocedure used in Example 1. The resulting film was 0.12 mm thick.

EXAMPLE 17

Following the procedure of Example 12, a 100 ml solution for theadhesive layer was prepared. The solution was coated on top of a backingfilm prepared according to Example 1. The opening of the knife wasadjusted, taking into account the thickness of the backing film. Aftercoating, the layered film was dried at 130° C. for 15 minutes. A 0.27 mmlayered film of two layers was formed.

EXAMPLE 18

Following the procedure of Example 14, a bioadhesive film was prepared,except that the film was not fully dried. A backing film was preparedaccording to Example 1. The backing film was peeled off of its substrateand laminated on top of the bioadhesive film while still moist, andpressure was applied to seal the two films together. The pressureapplied on the films resulted in a good interfacial adhesion. A 0.38 mmlayered film of two layers was formed.

EXAMPLE 19

Following the procedure of Example 1, several solutions for backingfilms were prepared according to the compositions of Table 2 below.Following film formation, ¼ inch disks were die cut and set on adouble-sided tape. The tape was then positioned on a micro slide. Thekinetics of erosion were evaluated in water: the slide was plunged intoa 100 ml beaker of water stirred at a constant speed of 50 rpm. The timefor erosion was measured from the moment the disk was fully immersed inthe beaker of water. Percentages (%) refer to the concentration insolution.

TABLE 2 Weight (mg)/ Composition Thickness (mm) Erosion Time (min.) 12%HEC (Mw 9 × 10⁴) 17.1/0.14 21 10% HEC (Mw 9 × 10⁴) and 16.9/0.13 37 2%HEC (Mw 7 × 10⁵) 9% HEC (Mw 9 × 10⁴) and   17/0.14 75 3% HEC (Mw 7 ×10⁵) 11.75% HEC ((Mw 9 × 10⁴) and 17.1/0.14 69 0.25% HEC (Mw 1.3 × 10⁶)11.95% HEC ((Mw 9 × 10⁴) and 17.2/0.13 57 0.05% glyoxal (40% aq. sol.)11.99% HEC ((Mw 9 × 10⁴) and 17.3/0.14 65 0.01% propylene glycol

The results demonstrate that the erosion time varies, depending on thecomponents of the formulation, assuming a similar surface state for eachsample. Although water does not mimic the exact composition of saliva,and this experiment cannot precisely replicate in vivo residence times,the experiment provides an in vitro comparison of erosion times ofvarious compositions for use in practicing the present invention.

EXAMPLE 20

½ inch diameter disks having a thickness of between 0.19 and 0.21 mmwere administered to six healthy volunteers. The backing layer wasprepared according to Example 1, and the adhesive layer was preparedaccording to Example 15, some containing dyclonine HCl as the activepharmaceutical component, and others containing benzocaine as asubstitute. The adhesive layer was coated on top of the backing layer,forming a layered disk. The layered disk was set in the mouth, and thetime for erosion was measured from the moment the disk was set in place.

Participants were asked to evaluate the disk's handling and numbingeffect on a scale of 0 to 3, with 3 being very good, 2 good, 1 fair, and0 poor. Participants also evaluated the time necessary for adhesion; theresidence time; the foreign body sensation, if any, and its duration;and the erosion of the disk. Finally, participants were asked toevaluate the overall effectiveness of the disk and their overallimpression, as well as which pharmaceutical n component, dyclonine HCl(D) or benzocaine (B), they preferred. The results are described inTable 3 below.

TABLE 3 Foreign Pharma- Residence Body ceutical No. Handling AdhesionTime Sensation Numbing Dissolution Efficiency Overall Pref. 1 3 instant~1 hr <5 min. 3 did not + + B notice 2 2 instant ~1 hr <5 min. 3 didnot + + B notice 3 3 instant ~45 min. no 2 did not + + D notice 4 3instant ~45 min. no 2 at the + − D end 5 2 instant ~30 min. <5 min. 3 atthe + + D end 6 1 difficult ~15 min. <5 min. 2 did not − − D notice

The results demonstrate that although the handling of the disk may bedifficult for first time users, the adhesion is instantaneous, there isonly a minor foreign body sensation which disappears after a coupleminutes upon swelling of the disk, and numbing is effective.

EXAMPLE 21

A 1 kg preparation of a backing layer was made using 43.49% by weight ofwater, 43.49% by weight of ethyl alcohol, 0.02% of FD&C red dye 40, 12%by weight of hydroxyethyl cellulose (Mw 9×104) and 1% by weight of 40%glyoxal aqueous solution. Then another 1 kg batch of the backingsolution described at the example 1 was prepared. Using a Werner MathisLabcoater, the substrate (Mylar 1000D or other polyester films such as3M ScotchPak 1022) was set. 90 ml of the backing layer solution preparedaccording to example 1 was set in front of a knife over roll with anopening of 0.7 mm. The solution was then casted on the substrate andfilm dried for 8-9 min. at 130° C. Following the drying step, a 0.09 mmthick reddish film was the result. Then, the backing solution firstdescribed in this example was casted directly on the top of the firstlayer with the knife over roll technique using an opening of 0.8 mm. Theresulting bilayer backing film was 0.15 mm thick.

EXAMPLE 22

A preparation of a backing layer obtained as described in example 5 wascast using a knife over roll and dried for 8-9 min. at 130° C. Then apreparation of a backing layer using 43.49% by weight of water, 43.49%by weight of ethyl alcohol, 0.02% of FD&C red dye 40, 12% by weight ofhydroxyethyl cellulose (Mw 9×104) and 1% by weight of 40% glyoxalaqueous solution was coated directly on the top of the previous dry film(first layer was 0.05 mm thick). The resulting bilayer backing film was0.12 mm thick.

EXAMPLE 23

When a crosslinking agent is incorporated in the formulation, thermalcuring allows to further crosslink the material either before or afterthe bioadhesive(s) layer(s) have been casted. Thermal curing of thefilms is performed by exposing the films to a time-temperature cycle.For instance, the film obtained at the end of example 22 might beexposed to 150° C. for 5 minutes, 120° C. for 10 minutes or anytemperature/time which would accommodate the stability requirements ofthe film's components.

EXAMPLE 24

A preparation of a backing layer obtained as described in example 5 wascast using a knife over roll and dried for 8-9 min. at 130° C. Apreparation of a backing layer using 42.49% by weight of water, 42.49%by weight of ethyl alcohol, 0.02% of FD&C red dye 40, 11% by weight ofhydroxyethyl cellulose (Mw 9×104), 2% by weight of polyethylene glycol6000 and 2% by weight of propylene glycol was coated directly on the toof the previous dry film (first layer was 0.06 mm thick). The resultingbilayer backing film was 0.12 mm thick.

EXAMPLE 25

A preparation of a backing layer using 42.49% by weight of water, 42.49%by weight of ethyl alcohol, 0.02% of FD&C red dye 40, 10% by weight ofhydroxyethyl cellulose (Mw 9×104), 4% by weight of hydropropyl cellulose(Mw 5 105) was coated using a knife over roll technique. Then directlyon the top of the previous dry film (first layer was 0.07 mm thick) abacking preparation made from 42.49% by weight of water, 42.49% byweight of ethyl alcohol, 0.02% of FD&C red dye 40, 12% by weight ofhydroxyethyl cellulose (Mw 9×104) and 3% by weight of oleic acid, wascasted and dried. The resulting bilayer backing film was 0.15 mm thick.

EXAMPLE 26

A preparation for the adhesive layer was made using 45.6% by weightwater USP, 45% by weight of ethyl alcohol, 2% by weight hydroxyethylcellulose, Natrosol® 99-250 L NF (Aqualon), 2.9% by weight polyacrylicacid, Noveon® AA1 USP (BF Goodrich), and 4.5% by weight of sodiumcarboxymethyl cellulose, cellulose gum 7 LF PH (Aqualon). Thispreparation is a bioadhesive preparation but does not contain anypharmaceutical.

EXAMPLE 27

A 100 ml solution for the adhesive layer was made using 45.1% by weightof water USP, 45% by weight of ethyl alcohol, 1.8% by weighthydroxyethyl cellulose, Natrosol® 99-250 L NF (Aqualon), 2.6% by weightpolyacrylic acid, Noveon® AA1 USP (BF Goodrich), 4.5% sodiumcarboxymethyl cellulose, cellulose gum 7 LF PH (Aqualon), and 1% byweight terbutaline sulfate.

EXAMPLE 28

The film obtained following the example 25 is used as substrate for thefinal multilayer film of this example. The bioadhesive preparation ofexample 26 is directly casted on the film of example 25 and dried. Thenthe preparation of example 27 is cast on the top with a knife over rollsystem. The final four layer film is 0.240 mm. The composition of thisfilm limits the release of terbutaline in the oral cavity but notcompletely as the pharmaceutical can still diffuse through the sides. Inorder to avoid this side diffusion, we have to changed slightly thedesign has previously mentioned.

EXAMPLE 29

The film obtained following the example 25 is used as substrate for thefinal multilayer film of this example. The bioadhesive preparation ofexample 26 is directly casted on the film of example 25 and dried. Atrilayer film is thus obtained, the last layer being bioadhesive but notcontaining any drug. Then the preparation of example 27 is coated usinga mask and dried (the mask is a 0.500 mm polyester film in whichellipsoids have been die cut deposited on the trilayer laminate). Thisstep can be repeated if necessary. The mask is then delaminated. Theresulting film is tri/four layers film composed of a laminate backinglayer and a laminate bioadhesive layer in which the final componentincludes the pharmaceutical and is of a smaller surface as shown infigure. With this system, diffusion by either the sides or the back sideis limited and allows an unidirectional release of the drug into themucosal tissues.

EXAMPLE 30

Following the previous example but with fluocinonide instead ofpilocarpine HCl, the same type of film is constructed using a screencoating technique instead of using a mask. Others techniques such asdeposition of, spraying the solution or die cutting off the last layer,slot coating, or gravure coating, are satisfactory.

EXAMPLE 31

A 200 gram (g) backing solution (or backing collodion) for coating thebacking layer was made by using 84.865% by weight ethyl alcohol 190 F.,0.01% by weight of FD&C Red dye 40, 13.75% by weight of hydroxypropylcellulose, 1.25% by weight ethyl cellulose and 0.125% by weight ofdiethyl phathatate. This solution was prepared at ambient temperature byadding the ethyl cellulose to the solution of ethyl alcohol, dye, andand diethyl phathalate. The hydroxypropyl cellulose was then added andthe collodion stirred for two hours.

A two layered film was subsequently obtained using a labcoater/dryer. Ona Rexam 8024 substrate, 50 mL of the solution above was set in front ofa knife-over-roll-coating device. The wet film was then dried for 6minutes at 60° C. A second layer was directly coated on the top and thewet film was dried for an additional 6 minutes at 60° C. The final filmthickness was measured to be 130 microns.

EXAMPLE 32

A 200 g backing solution (or backing collodion) for coating the backinglayer was prepared as in Example 31 except that 84.74% by weight ethylalcohol 190 F., 0.01% by weight FD&C Red dye 40, 12.5% by weighthydroxypropyl cellulose, 2.5% by weight of ethyl cellulose, and 0.25% byweight diethyl phathalate was used.

A film was obtained as in Example 31 except that the film thickness was135 microns.

EXAMPLE 33

A 120 micron thick film was made in a similar manner as in Example 32except that a higher molecular weight grade of ethyl cellulose wasemployed.

EXAMPLE 34

A 200 g backing solution (or backing collodion) for coating the backinglayer was prepared as in Example 31 except that 84.74% by weight ethylalcohol 190 F., 0.01% by weight FD&C Red dye 40, 10% by weighthydroxypropyl cellulose, 5% by weight of ethyl cellulose, and 0.5% byweight diethyl phathalate was used.

A film was obtained as in Example 31 except that the film thickness was115 microns.

EXAMPLE 35

A 200 g backing solution (or backing collodion) for coating the backinglayer was prepared as in Example 31 except that 81.99% by weight ethylalcohol 190 F., 0.01% by weight FD&C Red dye 40 and 18% by weighthydroxypropyl cellulose was used.

A film was obtained as in Example 31 except that the film thickness was170 microns.

EXAMPLE 36

The disintegration time in water for the films of Examples 31 to 35 wasmeasured by placing the films in a bath of water at 37±2° C. As theresults in Table 4 show, the disintegration time varies with the ratioof hydroxypropyl cellulose to ethyl cellulose.

TABLE 4 Exam- Example Example Example Example ple 31 32 33 34 35Thickness 130 135 120 115 170 (microns) Disintegration 20-25 25-3035-40 >60 15-20 time (min)

EXAMPLE 37

A gel for the backing layers was prepared which contained 79.74% water,0.01% FD&C red dye 40, 0.05% sodium benzoate, 2.5% peppermint flavor,13.5% hydroxyethyl cellulose, and 4.5% hydroxypropyl cellulose byweight. The gel was then made into a two layer flexible backing film of0.17 mm in thickness by first coating a 0.8 mm thick layer of theformulation on a substrate and then drying it at 80° C. for 8 minutes. Asecond 0.8 mm thick layer was then coated directly on top of the firstlayer and dried at 80° C. for 8 minutes. A sample of the two layer filmwas found to disintegrate in water within 10 minutes. While not wishingto be bound to any theory, it was believed that the hydrophilic saltmodified the disintegration time and the hydroxypropyl celluloseimproved the tensile strength of the film.

A gel for the bioadhesive layers was prepared which contained 45.2%water USP, 45.3% ethyl alcohol, 1.6% hydroxyethyl cellulose, 0.6%hydroxypropyl cellulose, 2.8% polyacrylic acid Noveon© AA1 USP, 2.5%sodium carboxymethyl cellulose, 0.1% titanium dioxide, and 1.9%albuterol sulfate by weight. Using the gel, a first bioadhesive layer of0.5 mm was coated directly on top of the two layer flexible backing filmand dried at 60° C. for 8 minutes. A second bioadhesive layer of 0.7 mmwas then coated directly on top of the first bioadhesive layer and driedat 60° C. for 20 minutes. The final film was 0.330 mm in thickness,contained 5.92% water by weight, disintegrated in water in 15±3 minutes,and contained 1.46 mg/cm² albuterol sulfate. The final film alsoexhibited excellent tensile strength.

EXAMPLE 38

A gel for the backing layers was prepared which contained 42.49% water,42.49% ethyl alcohol, 0.02% of FD&C red dye 40, 14% hydroxyethylcellulose (Mw 9×10⁴), and 1% sweet peppermint by weight. Using the gel,a first backing layer of 0,7 mm was coated onto a substrate using aknife over roll technique. The layer was dried at 60° C. for 8 minutes.A second backing layer of 0.8 mm was then coated directly on top of thefirst backing layer and dried at 60° C. for 8 minutes. The final twolayer film backing was 0.20 mm in thickness.

A gel for the bioadhesive layers was prepared which contained 45.95%water USP, 45.95% ethyl alcohol, 1.6% hydroxyethyl cellulose Natrosol®99-250 L NF (Aqualon), 2.2% polyacrylic acid Noveon® AA1 USP (BFGoodrich), 3.4% sodium carboxymethyl cellulose cellulose gum 7 LF PH(Aqualon), and 0.9% albuterol sulfate by weight. Using the gel, a firstbioadhesive layer of 0.5 mm was coated onto the two backing layers anddried at 60° C. for 10 minutes. A second bioadhesive layer of 0.8 mm wascoated onto the first bioadhesive layer and dried at 60° C. for 20minutes. The final film was 0.260 mm thick, disintegrated in water in20±5 minutes, contained 5.6% water by weight and about 0.71 mg/cm² ofalbuterol sulfate.

EXAMPLE 39

A gel for the backing layers was prepared which contained 42.49% water,42.49% ethyl alcohol, 0.02% of FD&C red dye 40, 14% hydroxyethylcellulose (Mw 9×10⁴), and 1% sweet peppermint by weight. Using the gel,a first backing layer of 0.7 mm was coated onto a substrate using aknife over roll technique. The layer was dried at 60° C. for 8 minutes.A second backing layer of 0.8 mm was then coated directly on top of thefirst backing layer and dried at 60° C. for 8 minutes. The final twolayer film backing was 0.20 mm in thickness.

A suspension for the bioadhesive layers was prepared which contained45.95% water USP, 45.95% ethyl alcohol, 1.6% hydroxyethyl celluloseNatrosol® 99-250 L NF (Aqualon), 2.2% polyacrylic acid Noveon® AA1 USP(BF Goodrich), 3.4% sodium carboxymethyl cellulose cellulose gum 7 LF PH(Aqualon), and 0.9% testosterone by weight. The testosterone isinsoluble in the formulation and is added as a micronized powder whichstays in suspension. The viscosity of the formulation was lowered tofacilitate the coating step by adding 10% by weight of alcohol:water ina 1:1 ratio. Using the suspension, a first bioadhesive layer of 0.5 mmwas coated onto the two backing layers and dried at 60° C. for 10minutes. A second bioadhesive layer of 0.9 mm was coated onto the firstbioadhesive layer and dried at 60° C. for 20 minutes. The final film was0.310 mm thick, disintegrated in water in 20±5 minutes, contained 5.3%of water by weight and about 0.64 mg/cm² of testosterone.

EXAMPLE 40

The films obtained via Examples 38 and 39 are die-cut in ¼ inch diameterdiscs to be characterized and to be used for a systemic availabilitystudy in three dogs (20-25 kg spayed female bred hounds). One disc ofthe film to be evaluated is applied to the inside of the mouth on thebuccal mucosa. A slight pressure is applied for 10 seconds. Then, theoral cavity is examined to assure adherence of the film to the mucosaand over the course of the study, to monitor the erosion of the discs.Using an indwelling jugular catheter, blood samples are collected atspecific intervals. The serum is characterized by an ELISA assay in thecase of albuterol sulfate and by an RIA method for the testosteronestudy. Mucosal tissues at the end of the studies did not show any signof irritation.

After application of ½ inch diameter discs, systemic plasma levelsobtained at different intervals are given in nanograms per milliliterfor the mean of the three dogs. Drug loadings are 0.9 mg albuterolsulfate per disc and 0.8 mg testosterone per disc. Results are shown inTable 5 for the albuterol sulfate and in Table 6 for the testosterone.

TABLE 5 (albuterol sulfate) Time Mean Standard (minutes) (ng/ml)deviation 0 0.12 0.01 5 0.15 0.12 10 0.22 0.07 15 0.57 0.54 30 1.51 1.6160 6.01 4.75 90 8.90 3.99 120 11.66 2.97 150 11.22 3.49 180 9.90 1.21240 6.30 2.21 360 6.29 2.23 480 3.75 0.62 720 1.00 1.05

TABLE 6 (testosterone) Time Mean Standard (minutes) (ng/ml) deviation 00.00 0 5 2.21 1.48 10 4.68 2.55 15 3.81 2.06 30 2.87 2.32 60 3.73 3.3190 4.82 3.53 120 7.14 0.51 150 3.20 0.03 180 0.62 0.18 240 0.18 0.20 3600.12 0.18 480 0.02 0.04 720 0.01 0.01

These results illustrate that systemic delivery can be achieved with thepharmaceutical carrier devices of the invention. Moreover, thepharmaceutical carrier devices of the invention yield fast onset ofactivity, excellent bioavailability, and sustained delivery.

1. A pharmaceutical carrier device comprising a layered film having afirst water-erodable adhesive layer to be placed in contact with amucosal surface, and a second, water-erodable non-adhesive backinglayer, wherein said device is capable of having a pharmaceuticalincorporated within said first layer, said second layer, or both layers.2-33. (canceled)